Method and apparatus for envelope flap extension



June 6, 1967 J. A. HART'ZELL METHOD AND APPARATUS FOR ENVELOPE FLAP EXTENSION 2 Sheets-Sheet 1 Filed July 15, 1964 June 1967 J. A. HARTZELL 3,

METHOD AND APPARATUS FOR ENVELOPE FLAP EXTENSION Filed July 15, 1964 2 Sheets-Sheet 2 INVENTOR. JOHNA,.HAEIZEZL BY I I My United States Patent 3,323,792 METHOD AND APPARATUS FOR ENVELOPE FLAP EXTENSION John A. Hartzell, 4044 Sheridan Ave. S., Minneapolis, Minn. 55410 Filed July 15, 1964, Ser. No. 382,805 19 Claims. (Cl. 2712) My invention relates to envelope flap extension and more particularly to an improved method and apparatus for providing envelope flap extension.

At the present time, the emphasis on mass communication through mailing has provided an increased need for automated equipment to eliminate manual handling and increase speed of such communications. Intricate and complex machinery have been developed and are in use to facilitate this purpose. Similarly, in the field of envelope making, carton and box making, and the like, improved machinery has been provided to automate the manufacture of the same. In these various fields, the methods for providing flap folding, unit stacking and various lapping arrangements have required the design and use of intricate lever mechanisms and complex machinery.

The present invention is directed to envelope flap extension which facilitates or conditions envelopes in a stacked or lapped relationship to simplify the filling and sealing of the same in mass mailing through the use of automatic machinery. In the past this has been done primarily through manual operation. The present invention provides an improved method and apparatus for readily positioning the flap and the body of an envelope relative to an adjacent envelope in a stacked relationship such that the envelope flap is readily available for use in filling machinery. Envelope flap extension within the meaning of the present invention is the physical relationship of positioning the flap of an envelope around the flap of an adjacent envelope or to one side of the same, while the body of the envelope is positioned to the opposite side of the body of the adjacent envelope. The present invention permits the manufacturer of envelopes to package and ship its product in this position or condition to eliminate further handling of manipulation by the user prior to the filling of the envelopes.

In the present invention, the improved method of envelope flap extension is obtained by directing an envelope through a tortuous path to bend the flap end of the envelope and raise the flap of the envelope. The envelope speed of movement in the forward direction of movement of the envelope is then reduced to provide a lapped relationship with the preceding and succeeding envelopes. The simplified apparatus for performing this method requires only the use of a pair of rotating drums which rotate at different speeds with a deflecting plate between the drums, to direct the envelopes continuously and successively through curved or arcuate paths. This improved method and apparatus eliminates any complicated lever or linkage system normally required for raising the flap on the envelope. It thereby provides an improved structure which is simple in construction and presents no limitations on the speed of operation of the same.

It is therefore the principle object of this invention to provide an improved method and apparatus for envelope flap extension.

Another object of this invention is to provide an improved method and apparatus of envelope flap extension which permits continuous high speed operation of flap extension without injury to or marking of the envelopes.

A further object of this invention is to provide an improved apparatus for envelope flap extension which "ice is simple in design, reliable in operation and compact to facilitate installation and usage of the same.

These and other objects of this invention will become apparent from a reading of the attached description together with the drawings wherein:

FIGURE 1 is a side elevation view of the improved flap extension apparatus,

FIGURE 2 is a plan view of the improved flap extension apparatus,

FIGURE 3 is a sectional view of the improved flap extension apparatus taken along the lines 3-3 of FIG- URE 2, and

FIGURE 4 is a schematic diagram showing the improved method and operation of the flap extension apparatus.

The envelope flap extender is shown in plan and side elevation views in FIGURES 1 and 2 as incorporating generally a frame 10 having a discharge section or chute 11 connected thereto. Frame 10 is comprised of a pair of side panels 14 and 16 having inclined surfaces thereon between which is mounted a plate member 18 to define an inclined surface on one end of the frame. The plate member 18 is suitably secured to the side panels 14, 16 through means (not shown). Mounted on the plate member 18 are a pair of guide rails 20, 21 which are set in from the edge of the same and raised to define an input chute for the envelopes to be extended. The guide rails 20, 21 have suitable prong members 23 thereon which extend through apertures (not shown) in the plate member 18 to position the same thereon. As will be seen in the sectional view in FIGURE 3, the side panel members 14 and 16 making up the frame 10 are integrally connected with a base member 25 which suitably positions the side panel members in spaced relation. As will be seen in FIGURE 2, the plate member 18 is notched, as at 25, to fit around curved upstanding portions of the side panels 14 and 16 and the guide rails 20, 21 extend along the surfaces of the plate member and between the side panels 14 and 16. Positioned across the upstanding portions of the side panels 14 and 16 is an elongated flange member 30 which is suitably secured to the side panels through screw means 32 and extend across the end of the chute formed by the plate member 18 and guide rails 20, 21 for the purpose of supporting envelopes at the input end of the extender. Positioned at the end of the discharge chute and extending between the side panel sections 14 and 16 is a shaft member 35 mounting a first drum 36, the shaft member being suitably journaled in the side panels 14 and 16 and having an extension beyond the side panel 14, as indicated at 38, which extension mounts a pulley 39.

As will be seen in FIGURE 3, the drum 36' mounted on shaft 35 is positioned adjacent the extremity of the plate member 18 which is curved to follow the contour of the drum, such as indicated at 40. The portion 40, of the plate member 18 extending inside of and beyond the surfaces of the side panels 14 and 16 is not rigidly attached to the side panels and hence is flexible so that it can be displaced relative to the drum 36, if desired. In FIGURE 3, it will be seen that the base member 25 mounts an upstanding flange 42 which is suitably secured thereon by screw 43 and carries at its free extremity a supporting spring bias shaft 45 having a thrust head 46 thereon bearing against the free extremity 40 of the plate member 18 for positioning the same relative to drum 36. Drum 36 mounts a plurality of friction members 48 on the peripheral surface thereof in spaced relation for the purpose of gripping the envelopes and transmitting them from the input end of the extender through the extending apparatus as will be hereinafter noted.

' detent 56 therein, for purposes to be later noted. A second pulley 60, mounted on the shaft extension 55 and the pulleys 39 and 60 are drivingly connected by means of a belt member 62, indicated in FIGURES 2 and 3. As will be later noted, however, the pulleys 39 and 60 may be replaced by suitable gearing with a gear ratio therebetween to define for the slower speed of rotation of the drum 52 with respect to drum 36. The driving connection of the belt member with respect to the pulleys 39 and 60 is such to provide for the same direction of rotation of the drum with respect to the envelopes to be extended which is obtained by a reversed belt drive or inner-meshed direct gearing in a conventional manner.

Drum 52 also mounts a plurality of friction members 65 thereon in the same manner as drum 36. Thus, the drums 36 and 52 rotate, as seen in the sectional view in FIGURE 3, respectively counterclockwise and clockwise as indicated by the directional arrows thereon.

The drums 52 and 36 are driven by means of a motor, indicated at 70 which is mounted on the base of frame 10 and has associated therewith a drive pulley 72 and belt 73 connecting with a similar pulley 75 mounted on the inboard end of the shaft 50 adjacent the side panel 16. Energization of the motor 70 from a suitable electric source and through a suitable control (not shown) will cause the motor to drive the pulley 75 and rotate the drums 52 and 36 in the manner defined above. The relative pulley sizes provide (for a higher speed of rotation of the drum 36 relative to the drum 52 to provide the lapping function and relationship of the envelopes as will be hereinafter defined.

Positioned between the side panels 14 and 16 is a curved deflecting plate 80 which'extends between the side panels 14 and 16 and is disposed to one side of the drum 36 and adjacent or overlying the drum 52. The'plate in inclined and defines an upper limit for the travel of the envelopes through the flap extender. Plate 80 is supported by a pair of shafts 82, which are connected to the plate through suitable means such as screws (not shown), the shafts extending into brackets 84 and having a spring 85 encircling the same to bias the shaft. The bracket 84 serves as a guide for the shaft and the end of the shaft terminates in this suitable detent 86. The entire bracket assembly is mounted on a second shaft 88, which in turn is supported through a suitable bracket 90 on the side panels 14 and 16, the bracket 90 being threaded to receive a threaded portion of the shaft 88 such that the entire bracket assembly 84 and shaft 82 may be adjustably positioned on the side panels 14 and 16 to position plate '80 relative to the surface of the second drum 52. Further, this mounting permits the plate 80 to be deflected upwardly upon the application of pressure thereto and through the slidable mounting of the shaft 82 in the bracket 84. An adjusting knob 92, on each of the shafts 88 adjustably positions the shafts 88 in the supporting brackets 90 to adjust the ends of the plate 80 relative to the drum 52.

Also connected to the side panels 14 and 16 is a further rod like member 100 which is suitably connected to the side panels and extends parallel to the axis of the shafts 35 and 52 and beyond the end of the plate 80 being positioned slightly above the same. This rod like member 100 has a spring retaining member 102 con 'nected to the shaft and which mounts one extremity of a spring 103. Also mounted on the rod member 100 is a flat plate 105 having a pair of upstanding flanges 106 with apertures therein which fit through the rod member. The free extremity 107 of the spring 103 bears against the surface of the plate and deflects the same toward the drum 52 and a horizontal surface 110 of the discharge section or platform 11 for the flap extender. This flat or horizontal section, as will be best seen in FIGURE 1, terminates in an inclined section 112 with a vertical flange 114 positioned on and extending from the horizontal and the inclined sections 110, 112 for supporting the discharge member or chute 11. The inclined section 112 is designed to engage and mount on the surface upon which the flap extending apparatus is positioned and the opposite extremity of the discharge section includes detent prong like members 116 on either edge of the same which are adapted to mount into cooperating detent members 118 mounted on the edges of the side panels 14, 16 to position this end of the horizontal surface 110 of the discharge section 11 thereon. This provides for removable attachment of a discharge chute or section to the flap extender. I

The improved method and operation of the apparatus of the envelope flap extender will best be seen from the schematic diagram in FIGURE 4. A plurality of envelopes in the conventional side by side or stacked relationship with the flaps of each envelope bearing against the side of the same are mounted in the input end of the flap extender or positioned vertically on the inclined plate member 18. This positions the envelope on an inclined surface and adjacent the friction surface of the first drum 36, As drum 36 is caused to rotate on its shaft 35, the friction surfaces 48 engage the envelopes sequentially and continuously urging the envelopes down along the curved ortion 40 of the plate member 18 and between the surface of the drum 36 and the extension of the plate member to follow in the first arcuate or curved path. As will be noted in the schematic diagram, the portion 40 of plate 18 extends beyond the vertical center line of the axis 35 such that the envelopes are rotated through an angle of approximately 90 degrees. The rotation of the drum 36 is in such a direction as to cause the envelopes to move forward along the surface of the plate 18 and curved portion 40. Shown schematically in FIGURE 4 are a pair of geared surfaces 121, 122, representing an alternate geared construction of a driving relationship between the drums 52 and 36. The cooperation of the geared surfaces or the belt and pulleys as shown in FIGURE 3, provides for rotation of the drums 36 and 52 respectively in counterclockwise and clockwise directions or to provide for tangental motion of the envelopes in the same direction. The relative difference in the gearing 121, 122, or in the pulley sizes in FIGURES 2 and 3 provide for a slower speed of rotation of the drum 52 with respect to the drum 36. As each envelope is advanced along the curved extremity 40 of the plate 18, it reaches the extremity thereof, and the leading edge of the envelope is deflected downwardly by the deflecting plate 80, causing the envelopes to be bent at the trailing edge thereof. This bending action deflects the envelope and raises the flap thereof, such as indicated at 125, from the body of the envelope 124. The frictional engagement of the envelope on the opposite side by the periphery of the drum 52, causes the envelope to be advanced forward relative to the preceding envelope such that the body is positioned to one side of the body of the preceding envelope while the flap is positioned outside of or around the flap of the preceding envelope. The plate 80 is spring biased toward the drum 52 and urges the envelopes in the lapped relationship toward the drum 52. The lapped relationship is provided by virtue of the slowing down of the forward edge of the envelope relative to the former speed thereof, such that the envelopes form a stack between the drum 52 and the plate 80, This applies a force to the stack of lapped envelopes such that the drum 52 advances the same in a lapped and stacked relationship under the deflecting plate 80 and against the spring biased plate 105 onto the discharge section :11 or the horizontal surface 110 thereof.

Since there are no oscillating levers, fingers, or the like involved in raising the flaps of the envelopes, there "is no limitation on the speed of the continuous operation of this flap extender.The physical size of the envelopes and the speed of -rotation-of the drums 3'6, 52 will determine the quantity of envelopes that may be directed through the flap extender. The positive bending of the envelopes to raise the flaps thereof provides the flap extended condition which facilitates use of the envelopes in filling and sealing machinery.

It will be recognized Ihat'the improved method of .envelope flap extension may utilize modified apparatus other than that specifically disclosed herein. The concept of raising the flap of an envelope through bending of the envelope by directing it through a tortuous path and staggering the envelopes in a lapped relationship by varying the speed thereof through the tortuous path provides a simplified and reliable method for continuous flap extension. If it is desirable to operate the apparatus without the benefit of the motor 70, the tool receiving detent 56 on shaft 55 may mount a suitable handle by means of which the drum 52 and hence the drum 36 may be rotated manually to provide for extension of the envelopes. Adjustment of the curved section 40 of the plate 18 accommodates varying envelope sizes and the adjustable mounting of the plate 80 through the bias means controls the lapped relationship of the envelopes.

Therefore, in considering this invention it should be remembered that the present disclosure is intended to be illustrative only and the scope of the invention should be determined by the appended claims.

What is claimed is:

1. The method of providing envelope flap extension comprising: moving envelopes from a sideby-side relationship with the flap side up, rotating the envelope through a curved path, with the flap closest to the radius of curvature of the path, reversing the direction of travel of the leading edge of the envelope to cause it to follow a second curved path and such that the flap of the envelope is raised, slowing down the travel of the envelope in the second curved path and applying pressure to the envelope in a direction urging the envelopes toward said second curved path such that the envelopes are urged to follow the second curved path in a lapped relationship with the flap of each envelope positioned around the flap of the preceding envelope in the direction of travel.

2. The method of providing envelope flap extension of claim 1 in which the first named curved path of travel of the envelope substantially through an arc of approximately ninety degrees.

3. The method of providing envelope flap extension of claim 2 in which the second curved path is opposite in direction and curvature to the first curved path.

4. The method of providing envelope flap extension of claim 3 in which the movement of the envelopes through the first and second curved path is urged through frictional engagement with the envelope.

5. The method of providing envelope flap extension comprising, moving envelopes in a continuing sequence through an arcuate path such that the flap end of the envelope is bent and the flap is raised, and thereafter reducing the speed of movement of the envelope such that it is positioned adjacent the preceding envelope in a lapped position and with the flap around the preceding envelope.

6. The method of providing envelope flap extension of claim 5 in which the envelope when caused to move at the reduced speed is directed on a second and oppositely curved arcuate path from the first named arcuate path to position the envelopes in a lapped relationship.

'7. The method of providing envelope flap extension comprising, frictionally engaging the flap side of a plurality of stacke'denvelopes in a sequence and directing each in the sequence through a curved path while applying pressure on the opposite side of the envelope, directing the "envelope over a second curved path and frictionally engaging the leading edge of the envelope and reversing the direction of the-curved path of travel of the envelope to bend the envelope, and thereafter releasing the trailing edge of the envelope such that the raised flap is directed to one side of the preceding envelope while the body of the envelope is directed to the opposite side of the preceding envelope.

8. The method of providing envelope flap extension of claim 7 and including slowing down the speed of movement of the envelope in the second arcuate path.

9. The method of providing envelope flap extension comprising, frictionally engaging an envelope at an edge opposite the flap and directing it through a curved path, releasing the frictional engagement at the edge opposite the flap of the envelope and frictionally engaging the edge opposite the flap of the envelope to follow a second curved path as the flap edge is bent and then released such that the flap of the envelope is raised and the edge opposite the flap of the envelope is directed to one side of a preceding envelope as the flap is retained on the other side of the preceding envelope to provide a lapped and extended relationship.

10. The method of providing envelope flap extension of claim 9 and including the application of continuous pressure against the lapped and extended envelopes causing them to follow the second curved path.

11. An envelope flap extender comprising, a frame having an inclined surface thereon, a first drum mounted on the frame and positioned adjacent and above the lower extremity of the inclined surface, deflecting means mounted on said frame and positioned adjacent said first named drum and spaced from and extending above the extremity of the inclined surface, a second drum positioned on said frame with its axis of rotation below and to one side of the axis of rotation of the first drum, means drivingly connecting the two drums for rotation in such a manner that it will direct an envelope from said inclined surface, and means for simultaneously driving both drums to move envelopes from a position adjacent the first drum along said inclined surface and toward said deflecting plate such that said deflecting plate applies a pressure to the leading edge of the envelope and bends the trailing edge of the envelope to lift the flap thereon and such that the second drum moves the envelope in a lapped and extended relationship with the flap of the envelope positioned to one side of the preceding envelope while the body of the envelope is positioned on the opposite side of the preceding envelope.

12. The envelope flap extender of claim 11 and including friction surfaces on each of said first and second drums.

13. The envelope flap extender of claim 12 and including means for spring biasing the deflecting plate such that it is movable toward and away from the second drum upon pressures from the envelopes therebetween.

14. The envelope flap extender of claim 11 in which the extremity of the inclined surface adjacent the first drum is curved and extends beyond the vertical center line of the first drum.

15. The envelopev flap extender of claim 14 in which the first and second drums have different dimetrical dimensions such that the peripheral speed of the drum surface engaging the envelope is different between the two drums.

16. The envelope flap extender of claim 11 in which the means drivingly connecting the drums includes means for providing a slower speed of rotation for the second drum relative to the first drum.

17. The envelope flap extender of claim 16 in which the means for simultaneously rotating both drums includes motor means mounted on said frame and operatively connected to one of said drums.

18. The envelope flap extender of claim 11 and ineluding stop means positioned on said frame adjacent said first drum for positioning the envelopes on said inclined surface in a vertical side-by-side relationship to be frictionally engaged by said first drum, and means positioned below said extremity of the inclined surface for flexing the same to vary the spacing between the curved extremity and said first drum.

19. The envelope flap extender of claim 18 and including a biased drag plate positioned adjacent said second drum and beyond said deflecting plate in the direction .releasably connected to said frame for receiving the lapped and extended envelopes from said second drum;

References Cited UNITED STATES PATENTS 2,038,645

4/1936 Cherry et al. 2712 2,092,524 9/1937 Post 2712 2,267,574 12/1941 Post 2712 3,162,435 12/1964 Raslorguyeif et al. 2712 M. HENSON WOOD, m, Primary-Examiner.

ALLEN N. KNOWLES, Examiner. 

5. THE METHOD OF PROVIDING ENVELOPE FLAP EXTENDION COMPRISING, MOVING ENVELOPES IN A CONTINUING SEQUENCE THROUGH AN ARCUATE PATH SUCH THAT THE FLAP END OF THE ENVELOPE IS BENT AND THE FLAP IS RAISED, AND THEREAFTER REDUCING THE SPEED OF MOVEMENT OF THE ENVELOPE SUCH 